Roadway luminaire

ABSTRACT

A method of manufacturing a roadway luminaire is provided which includes the steps of molding an upper housing from a composite material and applying a reflective substance directly to an inner surface of a domed portion of the housing to create a reflector. The luminaire further includes a lower housing hingedly attached to the upper housing which supports a lens therein and is pivotable into an open position and latched to the upper housing in a closed position. Means are provided for mounting the luminaire to a pole.

This is a divisional application of application Ser. No. 08/813,747,filed on Mar. 7, 1997, now U.S. Pat. No. 5,941,632 which is acontinuation-in-part of application Ser. No. 08/610,575, filed on Mar.8, 1996, now U.S. Pat. No. 5,803,590.

FIELD OF INVENTION

The present invention relates generally to luminaires for outdoorlighting and more particularly relates to a roadway luminaire which iseasy to mount to a mast arm and easy to maintain due to a mounting armassembly, a twist-lock feature, a fool-proof power plug and a plug-inreplacement luminaire.

BACKGROUND OF THE INVENTION

Poles for supporting luminaires for the illumination of roadways,parking lots and the like differ not only in that they have either avertical end with a mast arm or an inclined end, but also in that thediameters of the poles vary. For example, some poles have approximatelya horizontal end, the end often being at an angle of 5° to about 15° tothe horizontal. This variety of pole construction results in thatluminaires are commonly manufactured and warehoused in a correspondingvariety of constructions. Accordingly, it would be advantageous to havea universal mounting device for mounting a luminaire to a pole or mastarm.

Additionally, current maintenance costs associated with roadwayluminaires is extremely high. Particularly, maintenance is usuallyperformed by licensed electricians to replace capacitors, ballasts,photoelectric controls, starters and complete luminaires. The averagecost to replace/install a luminaire is approximately three times thecost of the luminaire itself, e.g. the cost of three men, two trucks anda trailer. There have been efforts in the past to overcome some of themaintenance problems associated with roadway illumination. For example,U.S. Pat. No. 4,937,718 discloses a roadway luminaire having theelectrical components employed in the lamp ballasting circuitry mountedto a door member by means of a universal mounting bracket having adeformable planer construction. In this way, a variety of differentsized components can be mounted using the disclosed bracket.Additionally, U.S. Pat. No. 4,538,217 discloses a flood light luminairehaving all the electrical components mounted on a removable door castingto allow for servicing and maintenance. U.S. Pat. No. 4,791,539discloses a luminaire having quick-disconnect components which aremounted on an electrical plate detachably secured to a support plate ofthe luminaire. The plate includes a quick disconnect for detaching theelectrical plate from the support plate. However, maintenance of theluminaire is still costly and replacement of components of theballasting circuitry is difficult and time consuming.

Another disadvantage of known roadway luminaires includes thepossibility of replacing a luminaire with one of a different voltage.Currently, roadway lighting may be operated at voltages of 120, 208,220, 230, 240, 277, 347 and 480 volts throughout the world. Accordingly,it is quite possible when replacing or repairing luminaires to usereplacement parts rated for a different voltage. Thus, it would beadvantageous to provide a luminaire which includes a means for keyingthe luminaire so that it can only be replaced by a luminaire whichoperates at the same voltage.

Yet another disadvantage of known roadway luminaires is the "hot wiring"of the luminaire, thus making replacement difficult and dangerous. Inmost cases, rather than shutting off the power to the roadway lighting,the lighting is repaired with power being supplied to the luminaire.Accordingly, only licensed electricians with proper protective geargenerally perform replacements of luminaires. Thus it would beadvantageous to have a luminaire which can be safely and easily replacedeven with power being supplied to the luminaire.

In view of the present disadvantages of currently available roadwaylighting devices, it is desirable to redesign the luminaire to be easyto install and maintain, provide a fool-proof replacement system whichpermits only luminaires of same voltage to replace a damaged luminaireand to make installation and maintenance more cost effective.

SUMMARY OF THE INVENTION

It is an object of the present invention to allow safe and easyinstallation and maintenance of roadway luminaires.

It is a further object of the present invention to provide an improvedmounting system for a luminaire to a mast arm.

It is yet a further object of the present invention to provide a keyedpower plug receptacle for connecting the luminaire to the power supply.

It is yet another object of the present invention to provide a luminairewhich can be mounted to a mast arm assembly utilizing a simpletwist-lock feature.

It is still a further object of the present invention to provide aluminaire having a plug-in starter module located externally on theluminaire housing for ease of replacement.

It is yet a further object of the present invention to provide aluminaire including an internal leveling device for proper positioningof the luminaire.

In accordance with the present invention, a luminaire for mounting on apole, and more specifically, a roadway luminaire includes a mast mountdocking station. having a clamp for attaching to the pole at one end ofthe docking station and a keyed coupling means provided at an oppositeend of the docking station and the luminaire having a connecting plateprovided with keyways such that the luminaire is removably coupled tothe mast mount docking station by a twist-lock mating between the keysand keyways of the coupling means and connector plate. The mast mountdocking station further includes an electrical plug connector located atthe coupling end of the docking station and, the luminaire includes amating electrical plug connector for electrically connecting the mastmount docking station to the luminaire. Specifically, the supply voltageis coupled to the electrical plug connector in the mast mount dockingstation and the mating electrical plug connector in the luminaireprovides the supply voltage to the ballast circuitry and ultimately thelamp.

For ease of attachment of the mast mount docking station to the pole,the docking station includes a plurality of knock-outs for adapting tomast diameters of varying sizes. In this way, the mast mount dockingstation can be specifically adapted such that little space is leftbetween the mast and the docking station to prevent animals and the likefrom entering the docking station. The docking station more specificallyincludes an upper mast assembly and a lower mast assembly. The uppermast assembly includes the clamp for attaching the docking station tothe pole. The upper and lower mast assemblies are secured together bybolts such that the electrical plug connector mentioned above is securedtherebetween. Additionally, the docking station may include a series ofinclined steps located in the upper mast assembly to permit angles oftilt for leveling the luminaire.

With respect to the twist-lock feature, the luminaire may be coupled tothe mast mount docking station by a 15° to about 30° rotational movementof the luminaire with respect to the docking station. This rotationalmovement provides both electrical and mechanical connection Morespecifically, upon rotation, the power plugs of the mast mount dockingstation and luminaire, respectively, are electrically connected and thekeys of the docking station are mechanically connected to the connectorplate of the luminaire in the same motion. The luminaire also preferablyincludes a molded photoelectric control receptacle extending above a topportion of the luminaire and a molded capacitor compartment whichextends below a bottom portion of the luminaire to provide hand holdsfor performing the twist-lock mounting of the luminaire to the dockingstation

With respect to the electrical connectors, each of the connectors isprovided with a series of crenulations, each crenulation beingidentified with a specific voltage rating to cover the spectrum of allavailable international voltages. The twist-lock feature for mating theconnectors is provided with keyways which ensure that only correspondingvoltage rated connectors are operatively coupled together.

The roadway luminaire of the present invention also includes a lowerhousing in which the ballast circuitry is mounted to a surface thereofsuch that the starter receptacle opens externally to an assembled upperand lower housing assembly and the starter module includes a plug-inconnector to electrically couple the starter to the receptacle withoutthe use of tools. Likewise, the upper housing is provided with aphotoelectric control cell receptacle integrally molded to a top surfacethereof. The luminaire includes a plug-in photoelectric cell which canbe selectively inserted into the receptacle and replaceable without theuse of tools. Lastly, the lower housing includes a cavity for receivinga capacitor of the ballast circuitry. The capacitor is press-fit intothe cavity for insertion and/or removal without the use of tools.Accordingly, maintenance of the luminaire is simple and fast.

Also disclosed is a method of installing or removing a roadwayluminaire, the luminaire including a mast mount docking station forattachment to a pole mast. The luminaire and docking station havingmating twist-lock connectors, the method comprising the step of twistingthe luminaire with respect to the docking station to therebymechanically couple and/or release the mating twist-lock connectors. Themethod is further defined such that the luminaire and mast mount dockingstation include mating power plug connectors and wherein the step oftwisting the luminaire also electrically connects and/or disconnects themating power plug connectors.

Additionally, a method of manufacturing a housing for a luminaire isdisclosed. Specifically, the method includes the steps of molding acomposite to form the housing including a dome section surrounding anarea of the lamp; coating an inner surface of the dome section withurethane or enamel coating; vacuum metalizing the inner surface of thedome section with aluminum; and coating the inner surface of the domesection with acrylic or urethane to form a reflective surface.

The luminaire of the present invention also includes a mast mountingassembly including means for mounting the mast mounting assembly to apole at one end of the assembly and a coupling means at the opposite endof the assembly. The luminaire Includes a housing for mounting a lamp,the housing including a mounting means for mechanically coupling theluminaire to the mast mounting assembly. Additionally, the mast mountingassembly coupling means and luminaire mounting means preferably includecooperating telescoping alignment means for ease of assembling theluminaire to the mast mounting assembly. More particularly, thecooperating telescoping alignment means may include an alignment flangeon the luminaire and the mast mounting assembly may be dimensioned atits coupling means end to be slidingly fitted into the alignment flangeof the luminaire.

Furthermore, the mast mounting assembly may include a first power plugelectrically coupled to a supply voltage and the luminaire may include asecond power plug electrically coupled to a lamp socket. The cooperatingtelescoping alignment means may include the first and second power plugshaving cooperating telescoping portions for aligning the mast mountingassembly and luminaire upon mechanically mating together.

The combination luminaire and mast mounting assembly may also includecooperating interlockig engagement means to positively latch theluminaire to the mast mounting assembly upon mechanically coupling twocomponents. The cooperating interlocking engagement means may include aspring latch mounted on the mast mounting assembly and a cammedreceiving slot on the luminaire whereby upon twist-locking thecooperative mounting means on said luminaire and mast mounting assembly,the spring latch follows the cammed receiving slot into a locking recessthereby positively latching the luminaire and mast mounting assembly.Furthermore, the cammed receiving slot preferably includes a ledgeportion whereby moving the spring latch onto the ledge portiondisengages the cooperating interlocking engagement means so that theluminaire may be removed from the mast mounting assembly. Preferably,upon disassembling the luminaire from the mast mounting assembly, thespring latch automatically resets to a proper installation position.

The combination mast mounting assembly and luminaire of the presentinvention including cooperative engagement means for mechanicallycoupling the luminaire to the mast mounting assembly may further includea seal therebetween. More specifically, the luminaire preferablyincludes a flange having upstanding walls for receiving the seal. Theseal includes a cross-section such that a rear portion is substantiallysquare and a front portion is substantially frusto-conically shaped. Thesquare cross-section portion is received in the walls of the flange andthe frusto-conical shaped portion is compressed upon mechanicallycoupling the luminaire to the mast mounting assembly. The seal furtherincludes at least one projection thereon for providing an interferencefit relationship with the upstanding walls of the flange. Accordingly,the seal is easily positioned within the flange and can be easilyremoved for replacement by a new seal when necessary due to maintenance.

The roadway luminaire of the present invention is also disclosed asincluding an upper housing including a reflector and a lamp socket and alower housing including a lens. The lower housing includes a recessedarea therein for mounting a ballast to a pair of threaded bossesextending from a lower surface of the lower housing. The recessed areaprovides air flow completely around the ballast for cooling the ballastso that the ballast may operate at a lower temperature prolonging auseful life thereof. Additionally, the lower housing acts directly as aheat sink for heat generated within the enclosure formed between theupper and lower housings. Specifically, wind and ambient air temperaturehelps to directly cool the upper and lower housings of the luminaire.

Also disclosed is a method of manufacturing a roadway luminairecomprising the steps of molding an upper housing from a compositematerial, the upper housing including a dome portion such that an innersurface of the dome portion is molded having a reflector geometry, andapplying a reflective substance directly to said inner surface of saiddome portion to create the reflector. The step of applying a reflectivesubstance may further include the step of using a vacuum metalizationprocess to apply the reflective substance. The step of molding the upperhousing may include the step of molding first and second upper housingsections, the first section including the dome portion, and followingthe applying step, further includes the step of mechanically couplingthe first and second upper housing sections. Accordingly, only the firstupper housing section including the dome portion is provided to themanufacturing process including applying the reflective substance to thehousing. Reducing the size of the component part to enter themanufacturing process allows more component parts to be processed and,accordingly, reduces the manufacturing cost associated with the processof applying the reflective substance to the housing. The first andsecond sections of the upper housing may be joined using a lap joint anda series of threaded screws.

Also disclosed in the present invention is a reflector for use in theluminaire which includes a plurality of aiming bands arranged within thereflector. Each aiming band is angularly displaced along its surface inboth a horizontal and vertical axis with respect to the reflector.Furthermore, each of the successive aiming bands of the reflector arevertically stacked to form the reflector. Preferably, the reflector isformed directly on an inner surface of a dome portion of the luminaire.The reflector also includes six reflective sections including a houseside section, a street side section, a right and left side section, anda top right and top left side reflector section. The reflective surfaceis most efficiently applied to the upper housing using a vacuummetalization process.

The luminaire of the present invention may also include an upper housingand a lower housing which may be coupled to form the luminaire. Theupper housing includes a reflector and a flange substantiallysurrounding the reflector. The flange may further include an upstandingwall substantially circumscribing a central section of the flange. Thelower housing includes a lens in substantial alignment with thereflector of the upper housing. The lower housing also includes a gasketsubstantially surrounding the lens such that upon coupling the lowerhousing to the upper housing, the gasket is received in the upperhousing flange and said upstanding wall engages the gasket therebyforming an effective seal therebetween. The upper housing may alsoinclude a photoelectric control cell receptacle integrally molded in atop surface of the housing for selective mounting therein of a plug-inphotoelectric control cell without the use of tools.

The present invention is also directed to a method of mounting a lens ina luminaire comprising the steps of providing a housing including anopening therethrough and a rim around said opening providing an edgeportion for supporting a lens thereon, and adhering a gasket to thehousing and lens such that an edge portion of the lens and the edgeportion of the housing are trapped beneath the gasket thereby holdingthe lens to the housing.

A preferred form of the luminaire, as well as other embodiments,objects, features and advantages of this invention, will be apparentfrom the following detailed description of illustrative embodimentsthereof which is to be read in connection with the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the luminaire assembly including themast mounting assembly with the lower door of the luminaire in an openposition formed in accordance with the present invention

FIG. 1A is a side elevational view of a luminaire having a flat lensformed in accordance with the present invention.

FIG. 1B is a side elevational view of a luminaire having a globe lensformed in accordance with the present invention.

FIG. 2 is an exploded perspective view of the luminaire assembly formedin accordance with the present invention.

FIG. 3 is an exploded perspective view of the mast mounting assemblyincluding the female power plug of the luminaire formed in accordancewith the present invention.

FIG. 4 is an end view of the female power plug formed in accordance withthe present invention.

FIG. 5 is an end view of the male power plug formed in accordance withthe present invention.

FIG. 6A is a perspective view of an alternative lock-plate.

FIG. 6B is a side view of the lock-plate of FIG. 6A.

FIG. 6C is a cross-sectional view of a connecting end of an upperhousing formed in accordance with the present invention.

FIG. 7 is a partial cross-sectional view of the lower housing whereinthe lens is trapped under the gasket.

FIG. 8 is a longitudinal cross-sectional view of the upper housing.

FIG. 9A is a front view of a toggle-type latch.

FIG. 9B is a side view of the latch of FIG. 9A.

FIG. 9C is a cross-sectional view illustrating an intermediate latchformed in accordance with the present invention.

FIG. 10 is a bottom view of the upper housing illustrating the geometryof the reflective surface.

FIG. 11 is a cross-sectional view of the upper housing taken along linesA--A of FIG. 10.

FIG. 12 is an exploded view of section B of FIG. 11.

FIG. 13 is a top plan view of an O-ring seal formed in accordance withthe present invention.

FIG. 14 is a cross-sectional view of the O-ring seal shown in FIG. 13taken along lines 14--14.

FIG. 15A is a top plan view of a lamp socket bracket for use in aluminaire formed in accordance with the present invention.

FIG. 15B is a side elevational view of a starter for use in a luminaireformed in accordance with the present invention.

FIG. 15C is a top plan view of a lower housing hinge assembly.

FIG. 15D is a side elevational view of the lower housing hinge assemblyshown in FIG. 15B.

FIG. 15E is a cross-sectional view taken through the upper housing hookand lower housing hinge assembly of a luminaire formed in accordancewith the present invention.

FIG. 16 is a top perspective view of the lower mast assembly formed inaccordance with the present invention.

FIG. 17 is a top perspective view of the upper mast assembly formed inaccordance with the present invention.

FIG. 18 is a side elevational view of a female plug receptacle formed inaccordance with the present invention.

FIG. 19 is a cross-sectional view of a male plug for use in a luminaireformed in accordance with the present invention.

FIG. 19A is a cross-sectional view of an alternative male plug andmating female plug receptacle for use in a luminaire formed inaccordance with the present invention.

FIG. 20 is an alternative embodiment of a mast mounting assembly andluminaire formed in accordance with the present invention.

FIG. 21 is a top plan view of the reflector of a luminaire formed inaccordance with the present invention.

FIG. 22 is a cross-sectional view of the aiming band closest to thereflector opening taken through the center of the aiming band.

FIG. 23 is a chart illustrating the light flux emanating from the aimingband closest to the reflector opening as illustrated in FIGS. 21 and 22.

FIG. 24 illustrates an alternative embodiment of a roadway luminaireformed in accordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 illustrates a roadway illumination luminaire 10 which includes anupper housing 2, a lower housing 4 and a mast mounting docking station6. The upper housing 2 includes two sections. The first section is thedome section 8 which includes a lamp 12, lamp socket 14 and a reflectiveinner surface 16. The second section is the protective housing 18 forthe electronic circuitry and electrical components of the luminaire.

As illustrated in FIGS. 8 and 10, dome section 8 is formed separatelyfrom the protective housing 18 and joined together using a lap jointconstruction 3. This two-piece construction facilitates greaterutilization of the metallizing process used to form the reflective innersurface 16. More specifically, the smaller the component part placedinto the metalization machinery, the greater the capacity for themetallizing process thus reducing manufacturing costs. Since theprotective housing 18 does not require the metallizing process, it maybe formed separately from the dome section 8. To assist in alignment ofthe dome section 8 and protective housing 18, the protective housingincludes at least one peg which is received in mating holes or recessesformed in the dome section 8. Furthermore, the two sections are bondedalong the lap-joint and joined by screws to mechanically mate thesections.

Preferably, the upper housing 2 is formed of a long-life, weather andcorrosion resistant fiber reinforced polymer construction. Knownluminaires usually include separate reflectors that are typicallystamped of aluminum and are supported in the dome portion of theluminaire housing. In the present invention, the reflector 16 isintegrated into the upper housing 2. More specifically, the upperhousing is preferably a compression molded composite with the reflectivesurface geometry 51 being formed during the molding process.

The preferred embodiments of the upper housing 2 and reflective surfaceinclude either a natural housing finish or a simulated metal finish. Ina preferred embodiment of the upper housing 2, the interior reflectivesurface 16 is formed directly on the molded housing by applying basecoating with a urethane or enamel coating, then vacuum metalized withaluminum and top coated with an acrylic or urethane. Thus, a reflectivesurface is provided directly on the interior of the dome portion onlyand all other surfaces are unfinished. Furthermore, the upper housing 2may be pigmented grey during the molding process to achieve thesimulated metal finish discussed above.

The upper housing 2 also includes a photoelectric control cell socketfor receiving a plug-in photoelectric controller 24. The photoelectriccontrol cell socket 22 is integrally formed during the molding processin a top section of the upper housing to provide for an unobstructedline-of-sight for the photoelectric control cell 24. The socket ispreferably a standard three terminal, polarized, locking-type socket.

As shown in FIG. 1, the luminaire also includes a lower housing or doorassembly 4 which is removably coupled the upper housing 2 via hooks 26(FIG. 2) and detents 28 of the lower housing 4 which allows the lowerhousing or door to swing open exposing the inner portion of the upperhousing and an inner surface of the lower housing. The lower housing 4includes mounted thereon the ballast circuitry to electrically power theluminaire. The lower housing is capable of swinging to a closed positionenclosing the luminaire and is held closed via a latch 32. Preferably,the latch 32 can be released without the use of tools to open theluminaire for repair and maintenance.

Also shown in FIG. 1 is a lock-plate 46 which is fitted into the upperhousing at its mounting end. More specifically, in a first embodiment,the lock-plate 46 is held by a pair of triangular-shaped bosses 45attached to the side walls of the upper housing to provide a slotbetween the bosses 45 and a rear wall 47 of the upper housing 2. Thelock-plate 46 is then slidingly fitted in the receiving slot of theupper housing. The lock-plate 46 includes a central opening and a seriesof keyways 43 associated with the central opening for receiving the keysof mast mount docking station therein. The interrelationship of thelock-plate 46 with the mast mount docking station 6 will be describedlater in greater detail.

In a second embodiment, the lock-plate 46, as shown in FIGS. 6A, 6B and8, includes a series of tabs 49 extending perpendicular to a surface ofthe lock-plate for mating connection with a power plug 36. The powerplug 36 is held to the lock-plate tabs 49 using any known attachmentmeans, such as a spring clip 600 as illustrated in FIG. 6C. The powerplug 36 may be adjusted to accommodate different voltage requirements,as will be discussed later in greater detail, by releasing the springclip and rotating the power plug to the appropriate setting. Morespecifically, as illustrated in FIG. 6C which is a cross-sectional viewof the connection end of the luminaire, the spring clip 600 includesfirst and second ends which extend through tabs 49 on opposite sides ofthe lock-plate 46, at least one of the ends of the spring clip beingpositioned between two raised walls 602, 604 which identify a voltagerating. The spring clip 600 further includes an alignment loop 606 whichis inserted through a tab 49 which identifies the voltage rating of themale plug 36 and ultimately, the power supply voltage to the luminaire.Accordingly, the desired voltage rating is placed in alignment with thespring clip alignment loop 606 to positively identify the luminairevoltage rating. The spring clip 600 may be disengaged from the lockingplate without the use of tools to change the voltage rating of the plugto match the power supply voltage. In this embodiment, the lock-plate 46is adhesively bonded and screwed to the upper housing at its mountingend. The lock-plate 46 of the second embodiment similarly includes acentral opening and a series of keyways 43 associated therewith, thefunction of which is the same as the first embodiment, i.e., receivingthe mast mount docking station

Referring to FIG. 2, the luminaire 10 is illustrated in an exploded viewshowing each of the components in the luminaire. Specifically, FIG. 2illustrates the upper housing 2 having the integrally formedphotoelectric control cell socket 22 and hooks 26 for engagement withthe detents 28 of the lower housing 4. The upper housing 2 also includesa flange 35 surrounding the dome section in which an adhesive-backedfelt or Dacron-polyester gasket 34 can be fitted. The flange 35 alsoprovides a rain lip for preventing rain from entering the enclosedportion of the luminaire. The gasket 34 provides a "breathing seal"gasketing between the lens 35 of the lower housing 4 and the lampcompartment 8 of the upper housing 4 to allow superior filtration.

In an alternate embodiment, the gasket 34 is fitted to the lower housingas illustrated in FIG. 7. Specifically, the gasket 34 is positioned suchthat the lens and the edge portion of the lower housing are trappedbeneath the gasket. As illustrated in FIG. 10, the upper housing 2includes a raceway 100 for receiving the wires associated with the lightsocket mounted therein. The outer edge of the raceway provides a rib 102which extends into the center of the gasket 34 thus forming an effectiveseal between the upper housing and lower housing to keep the interiorspace cleaner, improving component life. The gasket 34 is preferably anadhesive backed felt gasket allowing the gasket to be attached directlyto the lens.

The upper housing 2 also provides a mounting surface for a power plug36. In the embodiment shown in FIG. 2, the power plug 36 is a male plugwhich is held in position within the upper housing by means of aunshaped clamp 38. Alternatively, the power plug is matingly coupled tothe series of tabs 49 provided on the lock-plate 46 illustrated in FIG.6 via a spring clip as earlier described. Thus, the clamp 38 can beomitted reducing the number of parts and enhancing the maintainabilityof the luminaire. The power plug 36 provides a connection means from theline voltage to the luminaire ballast circuitry. The terminals 37 of themale power plug 36 are keyed, the purpose of which will be describedlater in greater detail.

The upper housing 2 is further provided at its plug connection end witha groove for receiving an o-ring type seal 42. The groove is designed toinclude interference flanges 44 so that the seal 42 can be fixedlypress-fit into the housing without the use of a bonding agent The o-ringseal 42 provides for a water-tight seal between the luminaire and themast mount docking station 6. In the preferred embodiment, the seal 42is a specially designed seal as illustrated in FIGS. 13 and 14.

As shown in FIG. 13, the seal 42 in the shape of an O, includes a seriesof projections or cylinders 104 on the inner and outer edges forengagement with the interference flanges 44 of the groove in the upperhousing receiving end. FIG. 14 is a cross-sectional view of the sealillustrated in FIG. 13 taken along lines 14--14. The seal 42 includes asubstantially flat rear surface 106 for engaging the bottom surface ofthe receiving groove. The opposing edge of the seal 108 is substantiallyfrustoconically shaped. This seal 42 provides an environmental sealbetween the upper housing 2 and the mast mount docking assembly 6 uponinterconnection therebetween. Furthermore, the seal 42 absorbs shock bycausing a varying natural frequency to prevent harmonics which may betransmitted to a luminaire from the pole thus prolonging component life.

As previously discussed, the lower housing 4 is maintained in a closedposition with respect to the upper housing by means of a latch 32. Asshown in FIG. 2, the latch comprises a latching device 39 at one end andlances 41 at the opposite end. The lances of the latch allow the latchto be lockingly engaged into a corresponding integrally moldedreceptacle (not shown) in the upper housing, thereby eliminating theneed for additional hardware to mount the latch.

Alternatively, the latch 32 may be an external toggle-type latch,similar to latches commonly used on a lunch box Such a latch isillustrated in FIGS. 9A and 9B. The latch connection boss of the upperhousing is illustrated in FIG. 8. Accordingly, no tools would berequired to open the housing assembly to access the lamp or ballastcircuitry. The toggle-type latch provides for a positive locking meansclosing the upper and lower housing interface while being simple tomanufacture and operate. Furthermore, the toggle-type latch allows thelatch to be opened yet still hold the door from swinging completely openuntil the latch is disengaged from the door edge.

FIG. 2 also illustrates that the lamp socket 14 is connected to theupper housing 2 via a socket bracket 48. The socket bracket 48preferably includes three sets of mounting holes 47 thereby making therelationship of the light bulb with the reflector adjustable fordifferent roadway types, i.e., narrow road or wide road. A preferredform of the socket bracket 48 is illustrated in FIG. 15A The bracket 48includes a first slotted portion 110 for receiving a first bolt and asecond three-position slotted portion 112 for adjustably securing thebracket to the upper housing. The bracket 48 is designed to hold thesocket tilted with respect to a horizontal plane of the luminaire. Theelectrical wiring from the socket 14 to the ballast circuitry is trappedbetween the upper housing flange 35 and the gasket 34 thereby protectingthe wiring within the luminaires. Alternatively, when the gasket 34 ispositioned on the lower housing as previously described, the upperhousing flange 35 preferably includes interference ribs or a raceway 100therein such that the socket wiring is wedged within the raceway betweenthe ribs thereby holding them securely in place.

The lamp socket 14 is preferably positioned between approximately a15-25 degree angle with respect to a horizontal plane taken through thecenter-line of the upper housing 2. The adjustably position bracket 48and angled socket in combination with the geometric design 51 of theluminaire reflective surface 16 produces enhanced photometricperformance. More specifically, the luminaire has true horizontal cutoffperformance in photometric. The geometric design of the reflector 51, asillustrated in FIGS. 10, 11 and 12, is designed to have more uniformlight distribution over a wider area. The geometric design includes aseries of substantially triangular-shaped sections or corrugatedreflector top section 114 to eliminate hot spots directly under thefixture on the roadway while utilizing all energy. Furthermore, thegeometric design of the reflector is generally formed from a series ofirregular tangentially mating curved bands 120 on the sides of thereflector having varying angles with respect to the horizontal andvertical planes of the luminaire to provide optimum light distributionto the target area. The reflector design of the present invention alsoprevents uplighting or light above the horizontal plane of the reflectoropening. Accordingly, light pollution is decreased and driver safetyincreased especially under wet conditions. Additionally, unlike manyknown luminaires which include globe-style lenses having refractors, thelens 35 of the present invention is flat, providing a sleek appearanceto the luminaire, as well as reducing the surface area exposed to thewind and reducing light pollution. However, due to the design of thepresent invention, a globe lens may also be used with the sameadvantageous results.

The lower housing or door 4 as shown in FIG. 2 includes molded recesses57, 58 therein for receiving components of the ballast circuitry, namelya ballast 52 and a capacitor 54. The ballast 52 is fixedly attached tothe lower housing by means of bolts which are received in bosses 56extending upwardly from a base of the lower housing 4. The molded recess57 allows air to flow around the ballast 52 for cooling allowing theballast to operate at a lower temperature to improve efficiency. Therecess or cavity 58 for receiving the capacitor is dimensioned so thatthe capacitor 54 is press-fit into the cavity thereby eliminating theneed for any hardware to hold the capacitor in place. The capacitorcavity 58 may include molded ribs 62 which deflect to permit insertionand withdrawal of the capacitor, yet provide a fit snug enough to holdthe capacitor in place. Alternatively, the capacitor may be held withinthe cavity using a clip. The ballast 52 and capacitor 54 are closelyfitted in the lower housing allowing the overall size of the luminaireto be smaller than known luminaries and, accordingly, the lower housing4 preferably includes a heat shield (not shown) between the ballast andthe capacitor. The heat shield allows for reduced internal distancesbetween the components thereby reducing the size and cost of the future.

In some instances, it will be necessary to utilize large ballasts toaccommodate the voltage requirements of the luminaire. Such largeballasts may weigh more than ten pounds and place significant stress onthe lower housing to which they are mounted. To resist against flexingof the door in the area of a heavy ballast, the present invention mayinclude an intermediate locking means to work in conjunction with thetoggle latch to maintain the lower housing in closed relationship withthe upper housing. The intermediate latch 900 is preferably positionedbetween the lens 35 and the recess for the ballast 57 as shown in FIG.9C. FIG. 9C is a cross-sectional view taken through the intermediatelatch 900 with the lower 4 and upper 2 housing in the closed position.The intermediate latch 900 includes a lower end having a first portionbiased against the lower housing and a second portion 920 extendingdownwardly from the lower housing. The upper end of the intermediatelatch extends through a slot formed in the lower housing and has a bentend section 930, which, when the lower housing 4 is closed onto theupper housing 2, rides along the outside of the gasket receiving flange940 thereby positively locking the upper 2 and lower 4 housings. Todisengage the intermediate latch 900, the second end portion of thelower end of the latch is manipulated to unlatch the bent end section930 from the flange 940. Once unlatched, the door may be opened toperform maintenance and repair.

Referring to FIGS. 1A and 1B, the luminaire of the present invention isshown in a side plan view. FIG. 1A illustrates a luminaire having thedoor 4 in the closed position with respect to the upper housing 2 andutilizing a flat lens. The door 4 is maintained in a closed, lockedposition by the toggle latch 32. Also illustrated in FIG. 1A are themolded receptacles 57, 58 for receiving the ballast and capacitor,respectively. The receptacles extend below a bottom plane of the lowerhousing 4. The alignment flange 162 is also illustrated in FIG. 1A. FIG.1B is identical to FIG. 1A, except the luminaire is shown using aglobe-style lens 35'. FIG. 24 is a side perspective view of theluminaire illustrated in FIGS. 1A and 1B with like component partsnumbered the same.

The lower housing 4 further includes a starter receptacle 61 integratedtherein. Preferably, the starter receptacle is molded directly into thelower housing 4 and the contacts for the receptacles are slidinglyfitted therein. The starter 63 is part of the ballast circuitry of theluminaire. A common failure mode among luminaires using the circuitry ofthe present invention is starter failure. In known luminaires, thestarter is generally bolted to the inside of the luminaire requiring theluminaire to be disassembled to replace the starter. In order to makemaintenance of the luminaire of the present invention simple and fast,the starter 63 plugs into the starter receptacle 61 from outside theluminaire housing. The starter 63 includes male terminals 65, preferablythree 1/4" faston terminals, which are received in the mating femalestarter receptacle 61. In order to further protect the starter 63 fromthe elements, the starter 63 is positioned within a molded starter case67. The starter case 67 and receptacle 61 preferably also include asnap-lock feature to ensure good mating contact between the maleterminals on the starter 63 and female receptacle. As illustrated inFIG. 15B, the snap-lock feature is achieved by molding snap-lockreceptacles or slotted openings into the lower housing duringmanufacture and molding on the starter case 67 corresponding matingsnap-lock connectors 69 or cantilevered fingers having projections 71 atthe distal ends thereof for engaging the slotted openings in the starterreceptacle. In the preferred embodiment of FIG. 2, the starter 63, whichincludes a printed circuit board potted in epoxy to reduce damage fromwater, dirt, vibration and heat molded within the starter case 67,extends downward from the bottom of the lower housing 4 when the lowerhousing is in a closed position with respect to the upper housing 2.Accordingly, the starter 63 is protected by the luminaire from directcontact with the elements, yet is easily and readily accessible formaintenance purposes (inspection and/or replacement). Additionally, notools are necessary when changing the starter due to the snap-lockfeature which eliminates any hardware for mounting the starter to theluminaire. Advantageously, the starter may be made to include a printedcircuit board positioned within the starter case which is surrounded bya potting material to reduce the occurrence of temperature, moisture andvibration failure.

The ballast circuitry in the lower housing 4 is electrically connectedto the upper housing 2, i.e. the lamp socket, via a multiple pinconnector (not shown). Most known luminaires have the ballast circuitrymounted in the upper housing whereas the present invention mounts allthe components of the ballast circuit in the lower housing. This designallows for easy maintenance when the lower housing or door 4 is swungopen. Furthermore, the entire lower housing assembly including theballast circuit may be replaced simply by unplugging the multiple pinconnector and lifting the lower housing off the upper housing hooks 26.Alternatively, the type of luminaire can be changed by replacing thelower housing with one having a different ballast circuit. Accordingly,the maintenance procedure for the luminaire of the present invention isgreatly simplified. To repair a failed luminaire, the maintenance workerwould check the lamp, the photoelectric control cell and the starter. Ifnone of these appear to be the problem, the ballast or capacitor may bereplaced or the entire lower housing 4 can be replaced. Alternatively,the entire luminaire can be replaced by twisting the luminaire 10 offthe mast mount docking station 6 and twisting on a new one. Thetwist-lock feature of the present invention will be described in greaterdetail below.

Referring to FIGS. 15C and 15D, the mating hinge 150 of the lowerhousing 4 is shown in detail. This hinge design is an alternative designto that shown in FIG. 2. More specifically, the hinge 150 includes acamming rib 152 and hinge engagement ribs 154. The hinge includes acentral rod 156 which is seated within the upper housing hook 26 whenassembled. To improve operability of the lower housing hinge 150 whenopening the luminaire on a table top, the camming rib 152 allows thelower housing or door to be opened without binding even though beinginverted. The slotted portion 158 next to the camming rib 152 is seatedwithin a lower ledge of the upper housing. The upper housing ledge, uponopening of the door 4 rides along the rounded camming rib 152 to preventbinding. The hinge engagement ribs 154 extend to engage the roundedsurface of the upper housing hook 26 preventing the door from beingremoved until the door is opened more than approximately 135° from theclosed position. Once the hooks 26 clear the hinge engagement ribs 154,the door 4 is free to be lifted away from the upper housing for repairor replacement. The hinge engagement ribs 154 provide a mechanical meansfor maintaining engagement of the upper and lower housing until suchdisengagement is desired.

As a further safety feature to maintain engagement of the hook 26 andhinge 150 of the present invention, a hinge clip 155 may be snapped overthe hook 26 as shown in FIG. 15E. The hinge clip 155 includes a roundedsection 157 substantially conforming to the shape of the hook and anupper portion 159 forming a substantially U-shaped portion having oneleg of the U extending across a top portion of the hook 26 holding thehinge rod positioned in the hook preventing disengagement therebetween.Upon opening of the lower housing, the hinge clip 155 prevents the lowerdoor 4 from being disengaged from the upper housing 2. To remove thelower housing 4 from the luminaire, the hinge clip 155 must first beremoved.

FIG. 3 illustrates an exploded view of the mast mount docking station 6formed in accordance with the present invention. The mast mount dockingstation 6 includes an upper mast assembly 64 and a lower mast assembly66. The mast mount docking station 6 is preferably formed of precisiondie cast aluminum. The upper mast assembly 64 is secured to the polemast by a fitter clamp 68 which is attached to the upper mast assemblyby a pair of bolts (not shown). Preferably, the fitter clamp 68 includesa gripper portion 79 having a roughened surface for better gripping apole or mast and to prevent over-rotation of the luminaire to the mastmount docking station upon installation. The mast mount docking station6 is capable of receiving 1 1/4' through 2" pipe without rearrangementof the clamp 68 or bolts. The upper mast assembly 64 also includes aseries of inclined steps 70 for receiving the end of the pole mast. Theinclined steps 70 are provided to allow angles of tilt for leveling theluminaire 10 with respect to a horizontal plane to produce maximum lightto the surface below. In the preferred embodiment, the inclined steps 70permit the greatest leveling adjustment presently available, i.e., ±6°with respect to the horizontal plane.

Furthermore, the upper and lower mast assemblies 64, 66, respectively,are provided at one end with a thin wall section 72 which may beremoved, similar to a "knockout" in a junction box, thereby allowing themast mount docking station 6 to receive mast arms of differentdimensions and to provide a relatively close fit therewith to preventanimals from entering the mast mount docking station. The upper andlower mast assemblies are provided at the opposite end with a keyedconnector 73, 75, respectively, for mating connection with the keyedopenings 43 of the twist-lock plate 46 shown in FIGS. 1 and 2. The keyedconnector 73, 75 includes a chamfered undersurface 81 to provide acamming action at the joint between the luminaire 10 and mast mountdocking station 6 compressing the seal 42 to produce a tight fittherebetween.

FIG. 3 also illustrates a power plug connector 74 for receiving theelectrical power conductors to operate the luminaire. The power plugconnector 74 is a female connector and includes three snap-in receptacleterminals 77 which receive the power conductors and are secured theretoby a screw on the side of the terminal. FIG. 4 is an end view of thefemale power plug connector 74. The plug serves as a receptacle for themale plug connector 36 of the luminaire (FIGS. 1 and 2). The outercircumferential edge of the female power plug is provided with a seriesof crenulations 76, each identified with a different voltage rating. Theplug is designed so that the intended voltage rating of the power supplyis oriented in, for example, a vertical position (along center line 75)to thereby identify the proper voltage for the particular luminaire tobe coupled thereto. The female receptacle 74 includes three receivingslots 78 which are generally circular or arcuate in shape and have aradially extending portion of the slot for receiving the terminals ofthe corresponding male plug positioned in the luminaire. The male plug36, shown in FIG. 5, includes a corresponding set of crenulations 82 andvoltages associated therewith. Thus, it will be readily apparent thatthe luminaire is designed for a specific voltage supply and will beconnectable only to a corresponding voltage female plug connector.Accordingly, if the female receptacle is coupled to a 480 V powersupply, a luminaire designed for a different voltage rating will not beable to be connected to the receptacle. This safety feature permits theluminaire to be a universal fixture which may be designed to operate atdifferent voltages, yet prevents a mismatch of a power supply andluminaire from being connected together.

The twist-lock feature of the present invention is provided by theinterface between the mast mount docking station 6 and the luminaire 10,such that the male and female plugs 37, 74, respectively, areelectrically connected upon the mechanical connection of the luminaire10 to the mast mount docking station 6. Preferably, the twist-lock isaccomplished by a rotational movement of the luminaire with respect tothe mast mount docking station ranging from about 15°0 to about 30°. Thetwist-lock feature provides both electrical connection between the maleand female plugs as well as mechanical connection of the luminaire 10 tothe mast mount docking station 6. Furthermore, the twist-lock featureprovides for fool-proof voltage matching between the power source andthe luminaire attached thereto. Specifically, the key/keyways of themast mount docking station 6 and locking plate 46 of the luminaire,respectively, in conjunction with the keyed plug and receptacle aredesigned so that only corresponding voltage male and female plugs may beelectrically connected. Additionally, mechanical stops are provided atthe key/keyway interface for providing a stop against over mechanicalrotation.

In an alternative embodiment illustrated in FIGS. 16 and 17, the upperand lower mast assemblies 64, 66 respectively, are designed to provide atelescoping feature for mounting a luminaire 10 onto the mast mountdocking station 6. More specifically, the lower mast assembly 66includes at its keyed end a contoured arcuate portion 160. The uppermast assembly 64 has a substantially arcuate center surface 170, whichupon connection to the lower mast assembly 66 forms a substantiallycircular-shaped end portion 160, 170 which is received in aninterconnection end of the luminaire. As illustrated in FIGS. 8 and 10,the interconnection end of the luminaire includes an outwardly extendingflange 162. Accordingly, upon coupling of the luminaire 10 to the mastmount docking station 6, the circular end portion 160, 170 of the mastmount docking station telescopes into the flange 162 of the luminaire asa guide to aid in the installation of the luminaire. This telescopingfeature also serves to protect the seal 42 from ultraviolet ray exposureand rain, prolonging seal life.

As illustrated in FIGS. 10 and 16, a locking means is provided forlockingly coupling the luminaire 10 to the mast mount docking station 6upon completion of twist-locking the components together. Morespecifically, as illustrated in FIG. 16, the mast mount docking stationlower mast assembly 66 includes a substantially triangular opening 164in which is mounted a torsion spring 166 having a first end 163projecting upwardly at a point closest to the keyed end of the lowermast assembly 66 and a second end 165 extending through a hole distallylocated with respect to the triangular opening 164.

The torsion spring includes a spiral looped portion between the firstand second ends to bias the first end toward the keyed end of the lowermast assembly. As shown in FIG. 10, the luminaire flange 170 includes ata lower surface a cutout 172 having a cam pattern to create a lockingmeans with the torsion spring 166 of the lower mast assembly. The flange170 includes indicia 174 indicating the proper orientation of thetorsion spring 166 therein for installation and removal of theluminaire.

Specifically, upon installation of the luminaire 10 onto the mast mountdocking station 6, the torsion spring 166 is first aligned with thecutout 172 and deflected rearwardly from its rest position by the firstcam section 175 of the cutout 172. Upon rotation of the luminaire withrespect to the mast mount docking station, the spring travels along thefirst cam section 175 until it springs forward reaching its lockedposition within the second cam section 176. In this position, theluminaire is fully locked in place with respect to the mast mountdocking station. To remove the luminaire, the torsion spring 166 ismoved to rest on the third cam section 177 of the cutout 170. With thespring 166 resting on the third cam section 177, the luminaire may betwisted off the docking station. The triangular opening 164 allows thespring 166 to guidingly move to rest on the third cam section 177thereby unlocking the locking means and facilitating removal of theluminaire 10 from the docking station 6. Since the torsion spring 166 isbiased to its resting position, the spring automatically resets toprevent the next fixture from being installed without locking. Thetorsion spring also acts as an alignment guide for initial positioningof the luminaire 10 onto the docking station 6 for installation.

To further facilitate mounting of the luminaire 10 onto the mast mountdocking station 6, the male plug 36 and female receptacle 74 aredesigned to include matingly telescoping portions to aid in alignmentfor installation. More specifically, as illuminated in FIG. 18, thefemale receptacle 74 includes a first substantially cylindricalprojection 180 located centrally on the receptacle and being surroundedby the female electrical receptacles. The second step portion 182 isalso substantially cylindrically shaped and a third step portion 184 isfitted within a mounting groove 173 formed in part in both the upper andlower mast assemblies 64, 66 respectively. Accordingly, when the upperand lower mast assemblies 64, 66 are coupled together, the femalereceptacle 74 is retainingly mounted in the mounting groove 173. Asshown in FIGS. 17 and 18, the upper mast assembly 64 includes aprojection 174 which matingly engages a slot 185 formed in the thirdstep portion of the female receptacle to maintain the proper orientationof the receptacle in the mast mount docking station. As previouslynoted, the female receptacle may be rotated to indicate the voltage ofthe power supply connected thereto. The mating projection 174 and slot185 on the receptacle ensure against unwanted rotation after the supplyvoltage is set.

FIG. 19 is a cross-sectional view of the male plug 36 which is mountedto the locking plate of the luminaire. The male plug 36 is formed withthree stepped recesses which matingly receive the stepped projections ofthe female receptacle 74. More specifically, the male plug 36 includes acentral axial bore 190, a first stepped recess 192 and a second steppedrecess 194. Upon mating of the luminaire 10 to the docking station 6,the projection 180 of the female receptacle is received in the centralaxial bore 190 of the male plug. The second step portion 182 of thefemale receptacle is received by the first stepped recess 192. The thirdstepped recess 194 provides a receiving space behind the locking plateto receive the keyed projections formed on the mast mount dockingstation 6. Accordingly, upon insertion of the luminaire 10 onto the mastmount docking station, the plug assembly provides a three-steptelescoping alignment means to properly orient the luminaire forinstallation on the docking station. Furthermore, as earlier discussed,the locking means comprising the torsion spring 166 and flange cutout172 provide further alignment means of the luminaire for mounting ontothe docking station.

FIG. 19A illustrates a modified plug/receptacle combination similar tothat shown in FIGS. 18 and 19. In FIG. 19A, the male plug 36 isillustrated in cross-section and includes a male ground pin 196 having atermination end coupled to a system ground. The female plug receptacle74 is shown in partial cross-section and includes a mating female groundpin receptacle 198. The female ground pin receptacle 198 has atermination end coupled to the housing of the luminaire to create aneffectively grounded device upon interconnection of the male plug 36with the female plug receptacle 74.

Referring now to FIG. 20, a further alternative embodiment of thepresent invention is illustrated. The fixture would again include aluminaire and a mast mount docking station 6' comprised of upper andlower portions 64', 66'. However, the mechanical and electricalconnection between the docking station 6' and the luminaire 10' aremodified from earlier embodiments. More specifically, the electricalconnection is made by mating a male connector 200 having contact blades210 which may be located at the connection end of the luminaire 10' witha docking station 6' female connector 220 for receiving the maleconnector 200. The male and female connectors 200, 210 may be adjustedto accommodate different supply and luminaire voltages by placing theconnectors in appropriate mounting holes 222. Accordingly, electricalconnection may be made only if the male and female connectors 200, 210are in alignment so that mismatching of voltages may be avoided.

To mechanically couple the luminaire 10' to the docking station 6', theluminaire may include a tab-shaped projection 212 on its undersurfaceand a latching finger 214 extending from a top portion of the luminaire10'. The docking station 6' may preferably include an elongate recess224 in the upper portion 64' for receiving the latching finger 214 ofthe luminaire and a latch 226 for latching engagement with thetab-shaped projection 212. Accordingly, upon mechanical coupling of theluminaire 10' to the docking station 6' by the latch means describedabove, the male and female electrical connectors 210, 200 becomeelectrically connected. Either the docking station or luminaire mayinclude a gasket 216 therearound to sealing mate the two components uponmechanical coupling together. Furthermore, as earlier discussed withrespect to other embodiments, it is possible to include telescopingcomponent portions to enhance alignment and provide greater mechanicalstrength to the coupling of the luminaire to the docking station.

As previously noted, the luminaire of the present invention providesimproved photometric over known luminaires. Several factors contributeto this improvement, the most significant of which is the luminairereflector. The reflector 16 formed in accordance with the presentinvention is best illustrated in FIGS. 8, 10, 11 and 21.

Referring to FIGS. 10 and 21, the reflector 16 is illustrated in a topplan view. The reflector geometry 51 is comprised of a plurality orhorizontally arranged bands 120 specifically designed to control boththe horizontal and vertical flux emanating from the reflector.Specifically, the shape or contour of these bands are curved to controlthe flux horizontally and vertical flux control is achieved by varyingthe vertical angle of the bands as they curve horizontally. The bands120 are arranged vertically coupled together with the edges ofsuccessive bands being tangent. In the preferred embodiment, each bandis approximately one-half inch in height. Each band is curved so thatthey are irregular with respect to the horizontal and vertical axes asthey progress around the reflector. Since each band is curved, no flatsurfaces exist, and undesirable flux concentrations known as "hot spots"are avoided.

Referring to FIG. 21, the reflector 16 can be divided into six mainsurfaces which control the distribution of light therefrom. The sixsections are defined as follows: house side reflector section 230 whichreflects the light towards the house side of the street; street sidereflector section 232 which reflects light across from the mounting poleand up and down the road; right side reflector section 234 whichreflects light up the road to the left of the fixture; left sidereflector section which reflects light down the road to the right of thefixture; top right side reflector section 238 which reflects light upthe road to the left of the fixture; and top left side reflector section240 which reflects light up the road to the left of the fixture. Thehouse side and street side reflector sections 230, 232 generally emitminimal light with the street side reflector section emitting more thanthe house side section. The right side section 234 and left side section236 emit the main portion of lighting, providing the high candle-powerrequired for fixtures mounted high above a roadway.

The reflector 16 having the geometry illustrated in FIGS. 10 and 21 ismost effectively formed by a vacuum metalization process over the moldedcomposite housing as earlier discussed. This process is more accuratelyrepeatable than hydroformed aluminum disks commonly used in roadwayluminaires. Specifically, the molded composite housing forms the bandsand a high purity metal having 85-90% reflectivity is applied directlyto the molded form to create the reflector. Hydroformed reflectors areknown not to be accurate and therefore use refractors to mask thoseinaccuracies. The present invention overcomes these disadvantages.Additionally, since the composite housing is an insulator, there is noneed for grounding the fixture.

Another advantage of a highly accurate reflector is that a smooth flatlens may be utilized as opposed to a lens requiring a prismaticrefractor. A smooth refractor or lens is more efficient since thecontrol is closer to the energy source. Accordingly, there is nouplighting or light above the horizontal plane of the reflector openingdue to a prismatic refractor. The highly accurate reflector of thepresent invention may be used in conjunction with either a smooth flator sag lens having no refractor.

Also shown in FIG. 21 is a preferred distribution of the aiming bandsforming the reflector. Each aiming band is angularly displaced along itscontoured length with respect to the horizontal and vertical axes. Morespecifically, each aiming band may be defined by a series of parabolicaiming sectors which direct light to a specific location on the groundas illustrated in FIG. 21. Referring to FIG. 23, the light distributionpattern for the right side reflector section aiming band closest to thereflector opening is illustrated. The light pattern from the aiming bandis shown in graphical form such that the y-axis is at 0° with respect toa horizontal axis of the luminaire and is perpendicular to the curbline. The x-axis is illustrated as being along the curb line, 90° withrespect to the horizontal axis. The grid in FIG. 23 is made up ofmounting heights, i.e., one unit is equal to the mounting height of theluminaire above the ground. The light pattern illustrated in FIG. 23corresponds to the light reflected by each aiming band sector of theaiming band closest to the reflector opening as shown in FIG. 21. Inview of the desired light pattern, each aiming sector varies in arclength around the reflector. As an example, to achieve a pattern of thelight being reflected by the lowest aiming band in the reflector to 90°with respect to the horizontal axis, the aiming band sector must be at a71° angle with respect to the vertical axis, i.e., the exit angle of thereflected light. Each aiming band sector varies in both the horizontaland vertical axes angles to achieve the desired light distribution.

Referring now to FIG. 22, which is a cross-sectional view of the rightside reflector section through a center of each of the aiming sectorsillustrated in FIG. 21, the angular variations of the aiming band withrespect to the horizontal and vertical planes of the reflector over itslength are shown. As shown in FIG. 22, the angular displacement of eachaiming band sector with respect to a horizontal plane varies to achievethe desired light pattern. For example, the aiming band sector whichdirects light to 95° from the horizontal axis (5° behind the curb linewith respect to a luminaire mounted at the curb line) has an angularhorizontal displacement of 93° 31' 32 " and the exit angle of the fightis 71.067°. Thus, in order to achieve the desired fight distributionpattern, each aiming band sector is specifically designed to be at acertain angle, both horizontally and vertically, with respect to thelight source. It will be appreciated by those skilled in the art thatthe cross-sectional view comprises a series of flats associated witheach aiming band joined together to form the reflector surface, eventhough the cross-section appears to be a curved surface.

Using flat aiming bands eliminates the probability of concentrated fluxwhich may occur in known reflectors due to manufacturing tolerances ormisalignment of the lamp within the reflector. Thus, the aiming bands ofthe present invention produce a' more uniform light distribution even ifmisalignment occurs. Furthermore, by molding the reflector geometrydirectly onto the inner surface of the upper housing and coating with areflective paint or the like, reflector geometries including undercuts,such as those in the top right and top left reflector sections, arepossible. Additionally, molding the reflector geometry directly in theupper housing makes it possible to generate the specific aiming anglesto achieve a desired light pattern. As will be appreciated by thoseskilled in the art, the angular displacement of the aiming bands formingthe reflector may be optimally designed to achieve a desired lightdistribution taking into account the size of the reflector with respectto the light source, the type of light source, the location of the lightsource within the reflector, the height of the fixture above the surfaceto be lighted and the type of light distribution pattern to be achieved.

The reflector design of the present invention also provides a thermaladvantage to the light fixture. More specifically, since the reflectoris formed by metallizing directly onto the interior surface of themolded composite housing, the housing acts as a heat sink to dissipateheat generated by the lamp. Accordingly, wind and outside air cool thehousing to dissipate heat generated by the lamp. In conventional designsusing hydroformed reflectors, there is generally an air space betweenthe reflector and the luminaire housing. This air space acts as aninsulator, similar to a double pane window, preventing heat from beingdissipated and effectively trapping the heat within the luminairehousing.

Another design feature of the present invention which permits improvedphotometric is related to the light source being mounted at a front endof the luminaire opposite to the connection end to the pole. Morespecifically, the lamp, which in most instances is a high pressuregaseous discharge lamp producing the greatest amount of light at anangle perpendicular to the arc tube, is mounted in the reflector withits base (threaded screw portion) pointed to the street and tilted atangle of approximately 25° above a horizontal plane. Tilting the lamptakes advantage of the natural lumen distribution of a linear lightsource, such as a high pressure gaseous discharge lamp. Specifically,tilting the lamp allows more light to be directly aimed at the roadwayfrom the lamp without having to redirect such light. Furthermore, sincethe socket blocks a portion of the light, by placing the socket withinthe house side reflector section, the light being blocked is thatdirected to the house side of the street which is the least importantportion of reflected light coming from the luminaire. The design of thepresent invention places the light socket higher within the reflectorcavity so that the tilted lamp makes it possible to get more lightbeneath the socket for redirecting to the roadway, virtually eliminatingdark spots. Naturally, the tilt or angle of the lamp will be optimallychosen to allow the lamp to be as close to the opening of the reflectoras possible based upon the specific shape of the lamp to be used.

Lastly, the reflector design of the present invention provides improvedroadway safety. The specific reflector design including a series ofaiming bands curved in the horizontal plane reflects light to bedistributed at a greater angle with respect to the horizontal plane fromthe fixture to produce less glare and light pollution. The reflectordesign directs light so accurately that the need for a prismaticrefractor was eliminated. Furthermore, the light distribution achievedby the luminaire of the present invention is uniformly even, with noconcentrated flux or hot spots. Since the reflector design of thepresent invention forms a wider arch on the roadway surface thantraditional fixtures, fewer fixtures are needed to light each road mile.To further optimize reflected light, the lower housing surrounding thelens in beveled to be in alignment with the reflected light so thatinterference therewith is kept to a minimum. The beveled cross-sectionalso provides maximum strength to the door assembly.

Accordingly, the luminaire of the present invention is simple to installdue to the two piece design, i.e., the mast mount docking station 6 andthe luminaire fixture 10, which are electrically and mechanicallyconnected via a twist-lock feature. Also, once the mast mount dockingstation is installed, repair and/or replacement of the luminaire issimplified and can be done "hot" since the power is connected to theluminaire by means of the mating power plugs. Furthermore, generalmaintenance of the luminaire has also been simplified by eliminating allunnecessary hardware, e.g. providing a plug-in photoelectric controlcell, a plug-in starter, and a lower housing door latch which requiresno tools to open. Additionally, the design of the lower housing whichincludes the ballast circuitry can easily be electrically disconnectedform the upper housing by unplugging a connector and being lifted offthe hooks of the upper housing for simple replacement. In thealternative, the entire luminaire can be quickly and easily replacedsimply by twisting off the old luminaire and twisting on a new one. Theluminaire of the present invention also provides power plugs capable ofbeing adapted to all presently available international voltages and afool-proof keying system to allow only corresponding voltage luminariesto be coupled to the mast mount docking station.

Various changes to the foregoing described and shown structures wouldnow be evident to those skilled in the art. Accordingly, theparticularly disclosed scope of the invention is set forth in thefollowing claims.

What is claimed is:
 1. A method of manufacturing a roadway luminaire,comprising the steps of:molding an upper housing from a compositematerial, said upper housing including a dome portion such that an innersurface of the dome portion is molded having a reflector geometry, and aflange surrounding the dome portion for receiving a gasket and providinga rain lip for preventing rain from entering the dome portion, theflange further including a raceway for receiving wires of the luminaire;applying a reflective substance directly to said inner surface of saiddome portion to create a reflector; molding a lower housing from acomposite material, said lower housing supporting a lens therein; andhingedly attaching said lower housing to said upper housing, said lowerhousing being pivotable into an open position and latched to the upperhousing in a closed position, wherein one of said upper and lowerhousing further includes means for mounting the luminaire to a pole. 2.The method as defined by claim 1, wherein the step of applying areflective substance includes using a vacuum metalization process. 3.The method as defined by claim 1, wherein the step of molding the upperhousing includes the step of molding first and second upper housingsections, the first section including the dome portion, and followingthe applying step further includes the step of mechanically coupling thefirst and second upper housing sections.
 4. The method as defined byclaim 1, wherein the step of molding thee upper housing includes thestep of molding a plurality of aiming bands on the inner surface of thedome portion to form the reflector geometry.
 5. The method as defined byclaim 1, wherein the step of molding the upper housing includes the stepof molding a plurality of undercuts on the inner surface of the domeportion to form the reflector geometry.
 6. A method of manufacturing ahousing for a luminaire, comprising the steps of:molding a composite toform an upper housing including a dome section surrounding an area of alamp and a flange surrounding the dome portion for receiving a gasketand providing a rain lip for preventing rain from entering the domeportion, the flange further including a raceway for receiving wires ofthe luminaire; coating an inner surface of the dome portion withurethane; vacuum metalizing the inner surface of the dome section withaluminum; coating the inner surface of the dome section with acrylicthereby forming a reflective surface; molding a lower housing from acomposite material, said lower housing supporting a lens therein; andhingedly attaching said lower housing to said upper housing, said lowerhousing being pivotable into an open position and latched to the upperhousing in a closed position, wherein one of said upper and lowerhousings further includes means for mounting the housing to a pole.